Curved lenses configured to decode three-dimensional content on television and computer screens

ABSTRACT

Curved lenses configured to decode three dimensional content and method of fabricating the same. The lenses decode three-dimensional content displayed on televisions or computer monitors. Sheets from which the lenses are cut have either (i) a polarizing axis of 0 degrees relative to horizontal and one sheet has a retarder axis at −45 degrees relative to horizontal and the other sheet has a retarder axis of +45 degrees relative to horizontal; (ii) a polarizing axis of −45 degrees relative to horizontal and one sheet has a retarder axis at 0 degrees relative to horizontal and the other sheet has a retarder axis of 90 degrees relative to horizontal; or (iii) a polarizing axis of +45 degrees relative to horizontal and one sheet has a retarder axis at 0 degrees relative to horizontal and the other sheet has a retarder axis of 90 degrees relative to horizontal.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No.12/495,754 filed Jun. 30, 2009, which is a continuation-in-part of U.S.patent application Ser. No. 12/350,092 filed Jan. 7, 2009, which claimsthe benefit of U.S. Provisional Application No. 61/019,545 filed Jan. 7,2008.

FIELD OF THE INVENTION

The embodiments of the present invention relate to lenses designed todecode three dimensional content displayed on television, movie,computer or similar screens or monitors.

BACKGROUND

Three dimensional movies for theatres have been around for decades. Withtechnological advances, three dimensional content is being developed fortelevision, computer monitors and home projectors. In the past, and eventoday, special glasses allow users to view three dimensional content.Flat paper eyeglasses using red and green film for lenses are theprimary glasses being used today. However, flat paper eyeglasses are notvery effective for facilitating the desired three dimension effect. Inaddition, the flat paper eyeglasses are not comfortable and aregenerally viewed as a novelty. Other flat lenses suffer from the samedrawbacks.

One advancement has been the development of linear and circularpolarization for decoding three dimensional content. Despite theadvancement, the lens and eyeglass technology has not advancedsignificantly.

Thus, there is a need for lenses that take advantage of the linear andcircular polarization technologies while more effectively creating thedesired three dimensional effect. Advantageously, the lenses andeyeglasses should provide improved optics and contrast while providinguser comfort and versatility. It is also beneficial if the lenses may bemounted into stylish frames.

SUMMARY

Accordingly, one embodiment of the present invention is a curved lensconfigured to decode three dimensional content comprising: a polarizinglayer laminated with a polymeric material layer on one or both sides; aretarder layer laminated to a front of the polarizer layer directly orto the polymeric material to form a sheet, said retarder layer alignedto decode a desired circular polarization; and wherein a blank cut fromthe sheet is curved using a thermoforming process or high pressureprocess into a lens configured to decode three dimensional content.

Another embodiment is a lens configured to decode three dimensionalcontent comprising: a polarizing layer laminated with a polymericmaterial layer on one or both sides; a retarder layer laminated to afront of the polarizer layer directly or to the polymeric material toform a sheet, said retarder layer aligned to decode a desired circularpolarization; wherein a blank cut from the sheet is curved using athermoforming process or high pressure process into an optical elementconfigured to decode three dimensional content; and wherein said opticalelement is utilized in an injection molding process whereby one or morethickness layers are added to the optical element to form said lens.

Another embodiment of the present invention is a method of fabricating acurved lens configured to decode three dimensional content comprising:cutting lens blanks from sheets of material comprising: a polarizinglayer laminated with a polymeric material layer on one or both sides; aretarder layer laminated to a front of the polarizer layer directly orthe polymeric material, said retarder layer aligned to decode a desiredcircular polarization, and wherein said blanks are cut to maintain aspecified alignment of a polarizing axis associated with said sheet;curving said blanks into lenses by: a. heating the blanks to adeformation temperature; and applying a vacuum suction and/or pressure;or b. applying high pressure.

In one embodiment, the retarder is a norbornene copolymer resin such asan Arton film (manufactured by JSR Corp.) or Zenor film (manufactured byZeon corp.). Conventional adhesives (e.g., pressure sensitive adhesives)are used to bond the layers forming the lens. In one embodiment, a hardcoating is applied to the front and back surfaces of the lens to allowfor normal cleaning and extended life. In one embodiment, a lensthickness is between 750 and 1500 microns. In another embodiment, thelens thickness is between 250 and 1500 microns.

In an embodiment intended to decode 3D content displayed on computerscreens or monitors, the blanks are cut from the sheet at a plus orminus 45 degree angle to correctly align the polarizing axis with thedisplay of content on the television or computer screen.

Other variations, embodiments and features of the present invention willbecome evident from the following detailed description, drawings andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 illustrate an exemplary specification sheet for a firstlens embodiment of the present invention;

FIGS. 3 and 4 illustrate an exemplary specification sheet for a secondlens embodiment of the present invention;

FIG. 5 illustrates a flow chart detailing one embodiment ofmanufacturing the lenses according to the embodiments of the presentinvention;

FIG. 6 illustrates a flow chart detailing a second embodiment ofmanufacturing the lenses according to the embodiments of the presentinvention; and

FIGS. 7 a-7 c illustrate various television and computer screen shotsshowing content parameters and polarizing axis alignment ofcorresponding 3D lenses.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles inaccordance with the embodiments of the present invention, reference willnow be made to the embodiments illustrated in the drawings and specificlanguage will be used to describe the same. It will nevertheless beunderstood that no limitation of the scope of the invention is therebyintended. Any alterations and further modifications of the inventivefeature illustrated herein, and any additional applications of theprinciples of the invention as illustrated herein, which would normallyoccur to one skilled in the relevant art and having possession of thisdisclosure, are to be considered within the scope of the inventionclaimed.

Traditionally flat lenses and frames have been used in 3D glasses. Oneproblem with the flat 3D glasses is that the lenses are distanced fromthe user's face and more particularly the user's eyes. Thus, light isable to enter the user's eyes from the top, bottom and side of thelenses reducing the visual acuity and contrast thereby reducing theeffectiveness and comfort of the 3D experience. This is especially trueat home or other locations outside of dark movie theatres. Moreover, thecurrent one-size-fits-all approach to flat 3D eyeglasses reduces thequality of the 3D experience and in many cases results in anuncomfortable fit for most users. Accordingly, the embodiments of thepresent invention seek to overcome the disadvantages of the prior artflat 3D eyeglasses by creating 3D lenses and eyeglasses which are moreakin to normal curved lenses and eyeglasses. Consequently, the lensesdescribed herein are generally thicker than traditional flat 3D lensesand curved to prevent ambient light from interfering with the 3Dexperience and allow for better fitting glasses. Conventional flat 3Dpaper lenses are 0.3 to 0.4 mm thick while the embodiments of thepresent invention are substantially in a range of 0.75 mm to 1.5 mm. Inan alternative embodiment, the lenses may be in range of 0.25 mm to 0.75mm for use with an injection molding process as described below. Thecurvature further enables a better fit on the user's head. In addition,the thicker lenses enable them to be mounted into stylish frames towhich people are more accustomed.

FIGS. 1-4 show specifications associated with lenses made utilizing theembodiments of the present invention. FIGS. 1 and 2 depict charts 100and 105 listing lens specifications according to a first embodiment. Thecharts 100 and 105 depict dimensions, including width 110 and length115, polarization angle 120, retardation angle 125, transmittancepercentage 130, polarizing efficiency 135, thickness 140 and retardation145. As shown in charts 100 and 105, the width ranges from 495 mm to 505mm; length from 700 mm to 710 mm; polarization angle from −1.0 degree to1.0 degree; retardation angle from 44.0 degrees to 46.0 degrees (or 134degrees to 136 degrees); transmittance percentage from 37.5% to 42.5% v;polarizing efficiency of 99% or greater; thickness of 1020 microns to1080 microns (or 1.02 mm to 1.08 mm) and retardation of 110 to 150 nm.Larger ranges are possible for each of the aforementioned categories.Charts 101 and 106 shown in FIGS. 3 and 4, respectively, depict similarlens specifications according to a second embodiment of the presentinvention.

Fabrication of the lenses is accomplished using lamination andthermoforming techniques. FIG. 5 shows a flow chart 200 detailing onemethod of fabricating lenses according to the embodiments of the presentinvention. At 205, sheets are formed and, at 210, lens blanks are cutfrom the sheets of material comprising: polyvinylalcohol polarizer film,polyethylene terephthalate or similar material laminated with triacetateon one or both surfaces (i.e., linear polarized film) and a retarderfilm laminated on a front surface thereof creating a circular polarizedfilm. While triacetate is one material that can be used, others includepolycarbonate, poly(methyl methacrylate), polystyrene, polyamide,cellulose acetate butyrate (CAB), cellulose acetate, cellulose diacetate(DAC) or cellulose triacetate (TAC), diacetate and similar stress-free(no birefringence) materials. The triacetate, diacetate or othermaterials may also be laminated onto the back (bottom) of the polarizerfilm to eliminate any unwanted retardation effects. A laminator machineforms the sheets of materials such that the axis of the polarizing filmand retarder film are aligned properly to small tolerances. In oneembodiment, the retarder is an Arton film (manufactured by JSR Corp.) orZenor (manufactured by Zeon corp.). Other materials, such aspolyurethanes, cellulose diacetate and polycarbonates, may also be usedas the retardation film. Adhesives bind the materials together. The sizeof the blanks is dictated by the intended frame size. A typical size is50 mm×70 mm. At 215, the blanks are placed into a thermoforming machinewhich heats the blanks to a deformation temperature (e.g., 90° C. to130° C.). At 220, the heated blanks are curved using thermoformingtechniques to an optically correct curved surface utilizing vacuumsuction and/or pressure. To generate the desired base curve (e.g., 4, 6and 8), a different combination of unique temperatures and times may berequired. Once formed, at 225, the curved blanks are cooled and removedfrom the machine. At 230, the blanks, now lenses, can be finished withconventional lens dry cutting machines. At 235, a hard coating isapplied over the curved lenses. The hard coating allows normal cleaningand extended use while protecting the operational materials forming thelenses. The hard coat may also be applied prior to the thermoformingprocess by using a thermoformable hard coat material. At 240,protective, removable sheets are applied to protect the lenses duringsubsequent operations including installation into frames, packaging andshipping. The protective sheets may also be applied to the sheets of thematerial prior to thermoforming process.

While thermoforming techniques are referenced in the flow chart 200,extreme pressures may also be used to create the curved lenses. Amachine known as the Wheel or similar machines generate extremepressures and can be used to curve a blank into a lens. The process isknown as press polishing whereby heat and pressure are applied to theblank via both sides of highly polished molds.

The triacetate and diacetate may comprises multiple layers themselvesand have qualities, including transparency, low birefringence,lightweight and strength. Moreover, triacetate and diacetate areresponsive to lamination and thermoforming processes and techniques asdisclosed herein.

For the circular polarized lenses utilized in the embodiments of thepresent invention the polyvinylalcohol polarizer film is tinted andstretched in a linear direction to orient the polymer molecules.Polyiodine molecules are commonly used to allow polarizing efficiencyand transmission to reach acceptable levels (e.g., >99% and >35%,respectively). Alternatively, dichroic dyes can be used to provideimproved resistance to heat and humidity, but may have slightly lowerpolarizing efficiency and transmission. Both embodiments can produce thedesired 3D decoding effect.

The curved lenses disclosed herein have numerous advantages over theflat 3D glasses of the prior art. The curved lenses provide a clearerand natural vision of 3D images with greater acuity and contrast. Moreparticularly, the curved lenses reduce light entering the user's eyesfrom the side, top or bottom of the eyeglass frames thereby increasingthe comfort and contrast associated with the viewed 3D images. Thecurved lenses can be fitted into commercial eyeglass frames to create astylish pair of eyeglasses.

In another embodiment, as shown in the flow chart 300 of FIG. 6, anoptical element is made using the aforementioned process for use in aninjection molded lens. Steps 305-330 coincide with steps 205-230described above except that the resultant blanks are thinner than thelenses formed using the steps of flow chart 200. At 335, the blankbecomes part of the final thicker lenses via an injection moldingprocess. In other words, a thinner version of the lens described aboveis used as an optical element to make low cost injection moldedpolycarbonate (or polymethylmethacrylate and polymide) lenses. In thisembodiment, the thermoformed optical elements are in a range of about250-750 microns with a final injected 3D lens in a range of about 1000to 2200 microns. Such lenses can be optically corrected with increasedthickness and rigidity. In one embodiment, a back polymer layer of thelens is the same material as the injected material to provide goodadhesion and reliability.

FIGS. 7 a-7 c show various television and computer screens depictingcontent and polarizing axis orientation or alignment for corresponding3D lenses. FIG. 7 a shows a television 400 displaying 3D content on ascreen 401 configured with a vertical polarizing axis 402 and retarderaxes 403, 404 aligned at −45 and +45 degrees, respectively, relative tohorizontal. Lenses 405, 410 have a polarizing axis 415 aligned at 0degrees (i.e., horizontal). A retardation axis 406 associated with theleft lens 405 is at −45 degrees (i.e., rotated clockwise) relative tohorizontal and a retardation axis 411 associated with the right lens 410is at +45 degrees (i.e., rotated counter-clockwise) relative tohorizontal. Accordingly, the left lens 405 and right lens 410 each allowonly similarly polarized content emitted by the television screen topass through thus creating the 3D effect. The configuration of lenses405, 410 is the same as the configuration of the movie lenses discussedabove.

FIG. 7 b shows a first computer 450 displaying 3D content on a screen451 with a polarizing axis 452 at +45 degrees from the horizontal andretarder axes 453, 454 aligned at 0 degrees (horizontal) and 90 degrees(vertical), respectively, from the horizontal. Lenses 455, 460 have apolarizing axis 465 aligned at −45 degrees from the horizontal. Aretardation axis 456 associated with the left lens 455 is at 90 degreesand a retardation axis 461 associated with the right lens 460 is at 0degrees relative to horizontal.

FIG. 7 c shows a second computer 480 displaying 3D content on a screen481 with a polarizing axis 482 at −45 degrees from the horizontal andretarder axes 483, 484 aligned at 0 degrees (horizontal) and 90 degrees(vertical), respectively, from the horizontal. Lenses 485, 490 have apolarizing axis 495 aligned at +45 degrees from the horizontal. Aretardation axis 486 associated with the left lens 485 is at 0 degreesand a retardation axis 491 associated with the right lens 490 is at 90degrees relative to horizontal.

Although the invention has been described in detail with reference toseveral embodiments, additional variations and modifications existwithin the scope and spirit of the invention as described and defined inthe following claims.

1. Glasses configured to decode three dimensional content comprising:two lenses having: a polarizing layer laminated with a polymericmaterial layer on one or both sides; a retarder layer laminated to afront of the polarizer layer directly or to the polymeric material toform a sheet, said retarder layer configured to decode a desiredcircular polarization; wherein a blank cut from a first sheet is curvedinto a first lens and a blank cut from a second sheet is curved into asecond lens wherein together the first and second lens are able todecode three dimensional content; and wherein the first and second sheetare configured such that: (i) the first and second sheet have apolarizing axis of 0 degrees relative to horizontal and one sheet has aretarder axis at −45 degrees relative to horizontal and the other sheethas a retarder axis of +45 degrees relative to horizontal; (ii) thefirst and second sheet have a polarizing axis of −45 degrees relative tohorizontal and one sheet has a retarder axis at 0 degrees relative tohorizontal and the other sheet has a retarder axis of 90 degreesrelative to horizontal; or (iii) the first and second sheet have apolarizing axis of +45 degrees relative to horizontal and one sheet hasa retarder axis at 0 degrees relative to horizontal and the other sheethas a retarder axis of 90 degrees relative to horizontal.
 2. The glassesof claim 1 wherein said polarizing layer, polymeric layer and retarderlayer have a combined thickness of 250-1500 microns.
 3. The glasses ofclaim 1 wherein said first and second lens in combination are configuredto decode three dimensional content displayed on a computer ortelevision monitor.
 4. Glasses configured to decode three dimensionalcontent comprising: two optical elements having: a polarizing layerlaminated with a polymeric material layer on one or both sides; aretarder layer laminated to a front of the polarizer layer directly orto the polymeric material to form a sheet, said retarder layerconfigured to decode a desired circular polarization; wherein a blankcut from a first sheet is curved into a first optical element and ablank cut from a second sheet is curved into a second optical element;wherein the first and second sheet are configured such that: (i) thefirst and second sheet have a polarizing axis of 0 degrees relative tohorizontal and one sheet has a retarder axis at −45 degrees relative tohorizontal and the other sheet has a retarder axis of +45 degreesrelative to horizontal; (ii) the first and second sheet have apolarizing axis of −45 degrees relative to horizontal and one sheet hasa retarder axis at 0 degrees relative to horizontal and the other sheethas a retarder axis of 90 degrees relative to horizontal; or (iii) thefirst and second sheet have a polarizing axis of +45 degrees relative tohorizontal and one sheet has a retarder axis at 0 degrees relative tohorizontal and the other sheet has a retarder axis of 90 degreesrelative to horizontal.
 5. The glasses of claim 4 wherein saidpolarizing layer, polymeric layer and retarder layer have a combinedthickness in a range of about 250-750 microns.
 6. The glasses of claim 5wherein said polarizing layer, polymeric layer, retarder layer and oneor more thickness layers have a combined thickness in a range of about1000 to 2200 microns.
 7. The glasses of claim 4 wherein said pair oflenses is configured to decode three dimensional content displayed on acomputer monitor.
 8. A method of fabricating curved lenses configured todecode three dimensional content comprising: cutting blanks from sheetsof material comprising: a polarizing layer laminated with a polymericmaterial layer on one or both sides; a retarder layer laminated to afront of the polarizer layer directly or the polymeric material, saidretarder layer aligned to decode a desired circular polarization, andwherein a first and second blank used to form a left and right lens arecut from first and second sheets configured such that: (i) the first andsecond sheet have a polarizing axis of 0 degrees relative to horizontaland one sheet has a retarder axis at −45 degrees relative to horizontaland the other sheet has a retarder axis of +45 degrees relative tohorizontal; (ii) the first and second sheet have a polarizing axis of−45 degrees relative to horizontal and one sheet has a retarder axis at0 degrees relative to horizontal and the other sheet has a retarder axisof 90 degrees relative to horizontal; or (iii) the first and secondsheet have a polarizing axis of +45 degrees relative to horizontal andone sheet has a retarder axis at 0 degrees relative to horizontal andthe other sheet has a retarder axis of 90 degrees relative tohorizontal; and curving said first and second blanks into lenses by:applying high pressure with controlled heating from both sides of apolished mold.
 9. The method of claim 8 further comprising fabricatingsaid lens with said polarizing layer, polymeric layer and retarder layerhaving a combined thickness of 250-1500 microns.
 10. The method of claim8 further comprising fabricating said lens with said polarizing layer,polymeric layer and retarder layer having a combined thickness of250-750 microns.
 11. The method of claim 10 further comprising utilizingan injection molding process to add thickness to said lenses.
 12. Themethod of claim 11 further comprising fabricating said lens with saidpolarizing layer, polymeric layer, retarder layer and one or moreinjection molding layers having a combined thickness of 1000-2200microns.